Universal outlet cover

ABSTRACT

A cover plate for hiding the socket faces of an electrical outlet. Particular embodiments of the cover plate are configured with multiple outlet configurations for use with more than one type of electrical outlet. The cover plate is mounted over the receptacle and has apertures for plug blades or thin, puncturable films over the apertures for the plug blades. Particular embodiments of the invention include thickness around the plug blade apertures for receiving plug blades of not more than 0.075 inches between the socket face and the front surface of the cover plate.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application also claims priority as a continuationapplication to patent application by Shotey et al. entitled “UNIVERSALOUTLET COVER”, Ser. No. 11/141,520, filed on May 31, 2005, presentlypending which will issue on Jun. 27, 2006 as U.S. Pat. No. 7,067,738,which application is a continuation-in-part application to patentapplication by Shotey, et al. entitled “RECEPTACLE-MOUNTED COVER PLATETO HIDE ELECTRICAL SOCKET FACE,” Ser. No. 10/966,456, filed on Oct. 15,2004, which is a continuation-in-part of patent application by Shotey,et al. entitled “RECEPTACLE-MOUNTED COVER PLATE TO HIDE ELECTRICALSOCKET FACE,” Ser. No. 10/583,925, filed on May 25, 2004, which is acontinuation of patent application by Shotey, et al. entitled“RECEPTACLE-MOUNTED COVER PLATE TO HIDE ELECTRICAL SOCKET FACE”, Ser.No. 10/283,586, filed Oct. 29, 2002 and issued on Jul. 13, 2004 as U.S.Pat. No. 6,761,582, which is a continuation of patent application byShotey et al. entitled “RECEPTACLE-MOUNTED COVER PLATE TO HIDEELECTRICAL SOCKET FACE”, Ser. No. 09/351,761, filed Oct. 11, 1999 andissued on Jan. 28, 2003 as U.S. Pat. No. 6,511,343, which is acontinuation of patent application by Shotey, et al. entitled“RECEPTACLE-MOUNTED COVER PLATE TO HIDE ELECTRICAL SOCKET FACE,” Ser.No. 08/775,382, filed Dec. 30, 1996 and issued on Oct. 12, 1999 as U.S.Pat. No. 5,965,846, the disclosures of which are hereby incorporatedherein by reference.

BACKGROUND OF THE INVENTION

1. Technical Field

The present invention relates generally to outlet cover plates, andspecifically to universal outlet cover plates that cover the socket faceof an electrical outlet and is adaptable for use with multipleelectrical outlet configurations using the same cover plate.

2. Background Art

In commercial stores, reducing the number of products on the storeshelves is a concern. A fewer number of different products (and theirSKUs) makes management of inventory and sale easier. In an effort toreduce the number of SKUs for in-use or weatherproof electrical outlets,bases with knock-out sections have been used that allow a portion of thecover plate to be removed to allow a particular configuration of asocket face to extend through the plate. Two examples of this are shownand described in U.S. Pat. Nos. 5,763,831 and 6,441,307, both to Shotey,et al. As an alternative to a cover plate with the removable sectionsbuilt into the plate, similarly configured adapters have been used with“while-in-use” bases, wherein the adapter plate includes one or moreremovable sections to allow for configuration of the base to fitdifferent configurations of socket faces. An example of this is shown inU.S. Pat. No. 6,642,453 to Shotey et al.

Conventional electrical outlet systems are made of several components,including a wall box and a receptacle that is typically composed ofpairs of sockets and a yoke. The receptacle is typically attached to thewall box which is attached to a framing member inside the wall. Thereceptacle is accessible through a hole cut in the wall. A cover platehaving apertures to allow the sockets to protrude is installed overthese components, typically with one or two screws. A conventional coverplate may be adapted with one or more hinge members along one or moresides to act as a base for a cover for in-use applications. Electricaldevices are plugged in by inserting the plug blades through alignedapertures in the cover plate and socket.

A cover plate is installed after construction. It is common practice toremove the cover plate during remodeling or redecorating so that it doesnot become damaged or defaced with paint drips and splatters, wallpaperpaste, or other decorating materials. The conventional cover plate iseasily removed by unscrewing the screw or screws that attach it directlyto the receptacle. However, the receptacle is not usually removed duringremodeling or redecorating because it is hard-wired into the building'selectrical system. Consequently, the receptacle and sockets are oftenleft exposed and the faces of the sockets become covered with paintsplatters and the like. Subsequent paintings only make the problemworse. Reinstalling the cover plate then emphasizes the paint-splatteredsurface of the outlet, as the defaced socket surface is compared to thepristine surface of the cover plate.

Further, cover plates are conventionally not available in a variety ofcolors and textures to match different room décor. Users sometimes coverthe cover plate with wallpaper or paint to match a room, but because theunderlying receptacle socket faces are also made in standard colors,usually white and ivory, the mismatched socket faces and cover platescause the outlets to be more conspicuous.

For outlet cover plates that have been designed to hide the socket face,each is designed for only a single configuration of outlet and,therefore, do not reduce the number of SKUs for a store. It would beadvantageous to have a cover plate that is configured to be adapted toany of a plurality of different socket face configurations yet stillhide the socket face.

BRIEF SUMMARY OF THE INVENTION

This invention provides a simple, easily-installed cover plate thathides the face of sockets by covering an electrical outlet, includingthe face of the sockets, but includes more than one outlet configurationfor the cover plate. Embodiments of the present invention include aplurality of plug blade apertures for a plurality of differentreceptacle configurations, a front surface, one or more thinned regionson the front surface and a back surface that contacts the socket face.Other embodiments of the present invention include configuration foronly a single receptacle.

In a simple form, embodiments of the present invention include a coverplate for an electrical outlet. The cover plate may include a pluralityof plug blade apertures extending therethrough. Alternatively, oradditionally, the cover plate may include at least a first configurationof break out elements identified thereon and at least a secondconfiguration of break out elements identified thereon. The secondconfiguration may be distinct from the first configuration forselectively placing one of the configurations in use by removing breakout elements from within at least one of the configurations to providethrough openings in the base. The first configuration may be identifiedon a first side of the base and the second configuration may beidentified on a second side of the base opposite to the first side.

The first configuration may be a first of a plurality of configurationson the first side and the second configuration may be a first of aplurality of configurations on the second side. The configurations mayinclude one or more of shapes for toggle, push and throw switch, andduplex, GFCI, decora, and round outlet configurations.

The configurations may include thinned portions forming outlines. Thethinned portions may have a thickness that can be broken by a screwdriver or an electrical component that is being connected to the outlet.In this regard, it is to be understood that the cover plate mayinitially include a cover plate that has one or more through openings ina first configuration for use without the need of preliminarymodification that can be modified if desired for alternateconfigurations by opening other aperture punch out regions.Alternatively, the cover plate may be provided initially as a “blank”cover plate. That is, the cover plate may be devoid of through openingsfor accommodating electrical outlets. Then, the through openings may beselectively formed in the blank as desired by a user through appropriateaperture punch out regions.

The outlines for the first configuration may be provided by score lines,indentations, coloration or other form of marking that is disposed on asurface of the first side of the cover plate, and the outlines for thesecond configuration may be provided by similar manner on a surface ofthe second side of the cover plate.

The cover plate may include a wall having a general thickness inportions used to cover the socket face in a range from approximatelytwenty thousandths to approximately seventy-five thousandths of an inch,the wall having the first and second configurations identified thereon.

A method of selecting at least one of a plurality of configurationsprovided on a cover plate of an outlet cover may include removingmaterial from within an identified portion of the base. The step ofremoving may include a step of breaking portions of the cover plate outof an identified area. The step of breaking portions of the cover plateout of the identified area may include breaking the portions out with agenerally rigid object. The generally rigid object may be part of a pairof pliers or a screw driver. The step of breaking may include forcingthe material in a first direction corresponding to a facing direction ofthe first side of the cover plate.

The foregoing and other features and advantages of the present inventionwill be apparent from the following more detailed description of theparticular embodiments of the invention, as illustrated in theaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a front plan view of a base of an outlet cover for anelectrical outlet in accordance with one embodiment of the presentinvention;

FIG. 1B is a back side plan view of the base shown in FIG. 1A;

FIG. 2 is a front plan view of a base of an outlet cover for anelectrical outlet in accordance with another embodiment of the presentinvention;

FIG. 3 is a front plan view of a base of an outlet cover for anelectrical outlet showing another embodiment having additional oralternative features in accordance with the present invention;

FIG. 4 is a front plan view of still another embodiment of a base of anoutlet cover for an electrical outlet including additional oralternative features;

FIG. 5 is a first cross-sectional view of the cover plate of FIG. 3taken along section line 5—5 for a modified embodiment where the coverplate is adaptable to a first electrical outlet configuration;

FIG. 6 is a second cross-sectional view of the cover plate of FIG. 2taken along section line 6—6 for a modified embodiment where no hingemembers are used and the cover plate is adaptable to at least twodifferent electrical outlet configurations;

FIG. 7 is a cross-sectional view of the cover plate of FIG. 1B takenalong section line 7—7 for a modified embodiment where no hinge membersare used; and

FIG. 8 is a flow diagram of a method of installing a cover plate for usewith an electrical outlet.

DESCRIPTION OF THE SEVERAL EMBODIMENTS

FIG. 1A is a front plan view of a cover plate 12 for an electricaloutlet in accordance with a particular embodiment of the presentinvention. As used herein, the term “cover plate” is intended tocomprise both cover plates with and without hinge members attachedthereto. The term “base” refers to the subset of cover plates with hingemembers coupled thereto and to which a lid may be coupled through matinghinge members coupled to the lid. While embodiments of the invention mayinclude cover plates configured for use with or without a hinged cover,the figures and examples provided herein generally show embodiments foruse with a hinged cover. It should be understood from the disclosureprovided herein, however, that the principle of providing a cover forthe socket face with its various configurations and embodimentsdescribed herein applies equally to cover plates with and without hingesassociated. Furthermore, the teachings and specifics of the inventionsdescribed in U.S. Pat. No. 5,763,831, issued Jun. 9, 1998 to Shotey etal. and U.S. Pat. No. 6,723,922, issued Apr. 20, 2004 to Shotey et al.are relevant to the present disclosure for molding and manufacturingprocesses and details on the covers and hinges, and the references as awhole are incorporated herein by reference for their relevant factualinformation.

The base 12 of FIG. 1A includes a generally flat plate 15 of materialfor hiding the socket faces of an electrical outlet or receptacle. Thebase plate 15 may be configured to be mounted directly to an electricaloutlet box. In cases where the base plate 15 hides the underlying outletsocket face, the base plate 15 may provide a covering that canadvantageously change the appearance of the electrical outlet.

While the base plate 15 is generally flat, it may also have any numberof a variety of contours including ridges or walls, hinges, and/orapertures for mating with an underlying socket face, receptacle orswitch, or for decoration, for example. The hinge elements, if used, mayprovide a pivotal connection for attachment of a weather protective lid,for example. It is contemplated, however, that in some embodiments ofthe present invention, hinge elements will not be used, and that someembodiments of the present invention will simply be configured asconventional wall plates with no additional hinge features. See, forexample, FIG. 5A. In embodiments where hinge elements are used to enableattachment of a lid, hinge styles other than those shown in the figuresof the present invention may be substituted as is known in the art. Thecontours, if used, may protrude or depress from front surfaces, backsurfaces, or edges of the base plate 15. However, the base plate 15 andits structure may all lie within a predetermined profile of maximumthickness in the front to back direction that forms the generally flatconfiguration. This thickness is much less than a height or widthdimension of the base plate 15. Therefore, the base plate may beconsidered to be generally flat even when it includes structure thatprovides a contour or texture.

As may be appreciated, there are a large variety of electricalconnectors and electrical switches having an equally large variety ofconfigurations of electrical outlet and switch configurations. Thus,there is a need for a base plate 15 that is capable of modification tomatch a large variety of electrical outlets and switches. Furthermore,it is advantageous to provide the base plate 15 in an overlying relationwith any of a variety of existing electrical outlet or switchconfigurations. The base plate 15 may also be configured in any mannerto advantageously hide all or part of receptacle or switchconfigurations that have not yet been discovered.

The base plate 15 may have through openings, or plug blade apertures,defined by structure forming edges at 29, 32, 35, 38, 41, and 44. Thesethrough openings may be configured to receive prongs of a plug while thebase plate provides a cover to hide a face of a plug receptacle. Atleast one additional configuration may be identified on the base plate15 by grooves, score marks or ink marks 18, 21 to define the socket faceregions 24 and 26. The socket face regions 24 and 26 may be removed fromthe base plate 15 to provide through openings in a manner described inU.S. Pat. No. 6,723,922, which is incorporated herein by reference.

Alternatively, the socket face regions 24 and 26 may be left to coverthe socket face of an electrical outlet onto which the cover plate isinstalled, and aperture punch-out regions 29, 32, 35, 38, 41, and 44 maybe removed to allow plug prongs to extend through the socket faceregions 24 and 26. Material may be selectively removed from within therespective outlines formed by these grooves or score lines. As may beappreciated, the material may be removed from the identified areasindividually or as a group. For example, a portion 47 of the materialwithin groove 29 may be punctured by a screw driver or some other tool.Alternatively, material may be punctured at one of the portions 47, 49,and 51 simultaneously by the prongs of a plug, for example. To enablepuncture of material from the portions 47, 49, and 51, the material inthese portions may be made relatively thin compared to the surroundingmaterial. In most cases it is desirable to have at least a portion ofthe material for the aperture punch out regions no greater than threefourths the maximum thickness of the surrounding material. However, itis believed that in some cases, depending upon the material, a simplescore line may be used in the prong aperture regions that would allowthe aperture punch out region to rupture when force is applied. Thethinned area may be the entire aperture punch-out region, it may simplybe the boarder of the aperture punch-out region, or it may be a scoreline within the aperture punch-out region that would allow an object,such as a plug, to puncture the region. In fact, these portions maycomprise a thin film of a thickness less than or equal to the thicknessof the base plate 15 at the grooves or score lines. Those of ordinaryskill in the art are familiar with plastics and metals manufacturingmethods and techniques whereby portions of a plastic or metal materialmay be made to be removed or punched out as needed for particularapplications of the present invention.

As shown in FIG. 1A, examples of grooves, score lines or ink marks(collectively “indicators”) on the front surface of the base plate 15are shown in solid lines. Alternatively, a single score line could beused within the aperture punch out regions near the center to create aweakness in that region. Additional indicators may be provided on a backsurface of the base plate 15 to provide for alternative removal ofmaterial to form through openings in any of a variety of additionalconfigurations. The indicators on the back surface of the base plate 15are shown in dashed lines in FIG. 1A. Accordingly, in FIG. 1A, a firstalternative configuration is provided by a rectangular score line 54. Asecond alternative configuration is provided by a round score line 57.Additional alternative configurations are provided by circular scorelines 60, 63, and 66. A further additional configuration may be providedby a rectangular score line 69 which may provide a through hole for alarge switch or a protruding portion of an existing cover, for example.Alternatively, one or more of the openings may be formed as an initialaperture to assist in removing the other knock out elements. Furtheralternatively, one or more openings may be provided as an initialconfiguration, such as for a duplex outlet that exposes a front face ofplug receptacle through the openings.

As may be appreciated, for the more common duplex outlet applications,corresponding configurations shown in solid lines in FIG. 1A may beused. To accomplish this, a user may selectively remove the socket faceregions 24 and 26, or the aperture punch-out regions 47, 49, and 51corresponding to the plug prongs. However, in applications havingswitches, round outlets, or cover structure corresponding to theconfigurations shown in the dashed lines in FIG. 1A, the base plate 15may be turned over and material may be selectively removed according tothe pattern on the second or back side (see FIG. 1B) to provide at leastone through opening corresponding to a particular target application.For example, referring to FIG. 1B, a user may selectively remove aportion 72 of material within the groove forming the rectangular outline54 to provide a through opening for a switch handle. Alternatively, auser may selectively remove any one of portions 75, 78, 81, and 84formed by grooves 57, 60, 63, and 66 respectively. These grooves, 57,60, 63, and 66 are configured to provide for removal of thecorresponding portions 75, 78, 81, and 84 of material and therebyforming through holes for electrical sockets and the like having sizesthat generally correspond to the circles formed by the grooves. Furtheralternatively, the user may selectively remove a portion 87 of thematerial bounded by the groove 69 of the base plate 15 to accommodate astructure of an existing cover in a through hole formed thereby.

FIG. 1B is a back side plan view of the base 12 of FIG. 1A. Hence thegrooves shown in solid lines in FIG. 1A are shown in dashed lines inFIG. 1B and vice versa. As may be appreciated from FIGS. 1A and 1B,providing indicators on both front and back surfaces of the base plate15 provides the advantage of enabling adaptation of the cover 12 to alarger variety of applications than if only a single side is used. As apractical matter, only a certain number of configurations can beprovided on the front surface of the base plate 15. Placing indicatorson a back surface advantageously enables generally double the number ofconfigurations for which the base 12 may be adapted. Configurations forthe front surface of the base plate 15 may be selected in accordancewith their excepted frequency of application. For example,configurations that are used more frequently may be placed on the frontof the base plate 15.

Alternatively, the configurations may be mixed and matched to providethe least amount of interference with each other. For example, ifcombining two particular configurations on the front surface tends tooverly weaken the base plate and thus cause inadvertent breaking out ofportions of material that are not intended to be broken out, then thetwo configurations may be advantageously separated and grooves be placedon opposite front and back sides of the base plate 15, respectively. Itis to be noted both the front and back surfaces of the base plate 15 maybe configured to provide an aesthetically appealing cover for anelectrical outlet or switch. The indicators may be provided as minorindentations or markings so that the outline of non-selectedconfigurations remaining on the base plate are relatively unnoticeable.On the other hand, the base 12 may be provided for outdoor use in whichdeeper grooves are considered to be of little or no consequence as faras aesthetics are concerned.

The material of the base plate 15 may comprise one or more of a metal, aplastic, or a composite. Depending upon the material, any of a varietyof tools may be used to knock out portions of the material. Each of theportions of material may be divided into smaller portions or knock outelements for enabling incremental removal of the material correspondingto a particular configuration. Such smaller portions or knock outelements are taught in U.S. Pat. No. 6,723,922 that has beenincorporated by reference.

While the knock out elements may be forced in either of a forward orrearward direction, removal is facilitated by forcing the knocked outelements in a direction away from the surface having the grooves thatdefine the knock out elements. That is, there is greater structuralstrength locally on the non-grooved surface. Thus, a preferentialstrength advantage is provided in which removal of knock out elements ofone configuration is facilitated over removal of knock out elements ofanother configuration. Thus, a user may selectively configure the baseplate 15 by providing through holes in a predetermined configurationcorresponding to particular indicators. The user may advantageouslyselect a direction of force that will preferentially cause removal of adesired configuration that is identified. The user may also select aparticular tool adapted to the particular material to be removed. Thus,a user may advantageously facilitate removal of particular knock outelements or aperture punch out regions in a particular portioncorresponding to the desired configuration. Further advantageously, theuser may alternatively select a configuration defined by the additionalindicators on an opposite side of the base plate 15.

The distinction made between knock out elements and aperture punch outregions is dependant primarily upon the width of the aperture formed.For knock out elements, the regions are generally fairly large such thatthe socket face can show through. For aperture punch out regions, thewidth of the region is generally just larger than the width of the plugaperture and much smaller than a knock out region. Often, because theaperture punch out region is punctured by pushing against the regionwith a narrow object, the material may not be fully removed from theregion and may remain attached with the aperture extending through it.For a knock out, the material is removed because its size is much largerand interferes. If the aperture is formed to allow for plug bladeaperture openings by simply pressing against the region, it is referredto as an aperture punch out region. It is anticipated that the thicknessof the aperture punch out region will generally be thinner than a knockout element, but this is not required for the embodiments disclosedherein provided the aperture punch out region is relatively easy toremove with an applied force. The GFCI button regions shown in FIG. 3are, therefore, also referred to as aperture punch out regions becauseno socket face is exposed in removal of that material.

While the configurations shown and described with regard to FIGS. 1A and1B may provide through openings adapted for use with duplex applicationsor switch apertures as described above, the groove 69 enabling knock outof portion 87 of material to form a large rectangular through openingmay be sized to correspond to Decora configuration applications. Thegrooves or score lines outlining circular configurations may beconfigured to provide through openings for round electrical sockets of avariety of sizes, for example.

FIG. 2 is a front plan view of a base plate 90. This alternativeconfiguration has a large rectangular outline that may be defined by agroove 93 and three plug receptacles, each including structure definingopenings through the base plate 90 in a configuration shown by lines 95,97, and 99. Thus, the three receptacles may provide existing throughopenings for receipt of plug prongs while the rest of the base plate 90may act as a cover that hides a surface of the plug face. Alternatively,the base plate 90 may include aperture punch out regions in areas withinthe lines 95, 97, and 99. Grooves may be provided at lines 95, 97, and99 to enable selective removal of three removable portions identified bylines 95, 97, and 99, or the regions may otherwise be thinned. Therectangular groove 93 and the plug receptacle regions defined by lines95, 97, and 99 are shown in solid lines in FIG. 2 in order to indicatethat the region identification, where used, is in the front surface ofthe base plate 90. Dashed lines 101 and 103 represent alternative oradditional portions that may be originally open or provided asidentified portions that may be punctured or removed using aperturepunch out regions or knock out elements as appropriate. These portionstogether with the portions defined by lines 95 and 97 may be open orpunctured in order to accommodate plug prongs of corresponding shapesand positions. Thus, the regions for providing through openings in thebase plate 90 for the three plug receptacles may have alternativeconfigurations.

The additional dashed lines 105, 108, 111, and 114 in FIG. 2 representindicators on a back surface of the base plate 90 similar to thosedescribed with regard to FIGS. 1A and 1B above. For example, a groove105 may be provided to enable breaking out of material to form a throughopening for a round receptacle. Grooves 108 and 111 outlining generallydiagonally disposed rectangular portions and a groove 114 outlining an“L” shaped portion may be provided to enable pucture of aperture punchout regions to accommodate an electrical connector of a similar shape. Agroove 117 outlining a smaller rectangular portion may be provided inthe back surface to enable breaking out and removal of material to forma through opening for a switch handle as described above. As alsodescribed above, the base plate 90 of FIG. 2 may be selectively turnedover to enable a user to view the additional configurations indicated.Furthermore, providing such indications on an opposing side facilitatesremoval of knock out elements and puncture of aperture punch out regionsto provide through openings corresponding to any of a variety of theadditional configurations.

FIG. 3 is a front plan view of a base plate 120 having duplex or twoplug receptacle configurations including through openings at 29, 32, 35,38, 41, and 44. Thus, the base plate 120 may be used to cover a face ofa plug receptacle, provide existing openings for receiving plug prongs,and provide for selective removal and puncture of portions correspondingto any of a variety of configurations that may be identified on the baseplate 120. Alternatively, the openings at 29, 32, 35, 38, 41, and 44 maybe replaced by aperture punch out regions of the base plate that may beidentified by indicators substantially corresponding to the solid lines29, 32, 35, 38, 41, and 44 of FIG. 3. These indicators are shown insolid lines indicating that they are disposed in the front surface ofthe base plate 120 similar to the configurations shown in FIGS. 1A and1B. Indicators 123 and 126 may also be provided in the front surface toenable selective puncture of material through an aperture punch out toprovide mounting apertures at respective longitudinal ends of the baseplate 120.

An indicator 129 may be provided in a back surface to alternatively andselectively provide a mounting aperture in a center of the base plate120. Indicator 132 may be provided in a back surface, for example, toidentify selective removal of material circumscribed thereby toaccommodate ground fault circuit intercept (GFCI) switches through knockout regions. The indicators 132 may be provided at respectivelongitudinal ends and a central portion of the base plate 120 tocorrespond with typical positions of GFCI switches on electricaloutlets. Each of the indicators 132 may include dividing segments thatdefine portions 135, 137, and 139 at each of the end and centralpositions. Thus, the user may selectively remove one or more of theportions 135, 137, and 139 depending upon the GFCI switches and theirpositions on an electrical outlet to be covered by the base plate 120.It is contemplated that other indicators, aperture punch out regionsand/or knock out elements may also be provided to accommodate otherconfigurations of GFCI switches or other outlet components orconfigurations.

FIG. 4 shows a base plate 142 having a groove 145 outlining a generallycircular configuration. Indicators 148, 151, and 154 outline aperturepunch out regions that may be ruptured or otherwise punctured toaccommodate prongs of an electrical connector of a particularconfiguration. The groove 145 may be disposed on a front surface or aback surface as has been described above. Alternatively, the portionsidentified by indicators 148, 151, and 154 may be replaced by throughopenings. Thus, the base plate 142 may have existing openings with edgescorresponding to the dashed lines at 148, 151, and 154 for receivingplug prongs.

FIGS. 5, 6 and 7 are, respectively, cross-sectional views of FIGS. 3, 2and 1B and use the respective reference numbers corresponding to thedescription of those FIGs. Additionally, thicknesses 200 and 203 areshown for each embodiment. While it is not required for everyembodiment, in particular embodiments of the invention, the thickness ofthe socket face region, or region of the cover plate directly coveringthe insulative socket face of an electrical outlet, has a thickness 200that does not exceed a predetermined thickness. In one specificembodiment, that thickness 200 is between 0.020–0.075 inches. Thethickness 200 may be of various shapes and sizes, so long as thethickness 200 does not exceed a predetermined maximum thickness. Thethickness of the socket face region of the cover plate is importantbecause it is the region through which plug blades are inserted andprovides the point of electrical contact for a corded plug in theelectrical outlet. It has been determined by the National Electric Codethat material over the socket face may increase the risk of fire andheating. Subsequent studies have shown that defining a maximum thicknessfor the socket face region of a cover plate ensures that the plug bladeswill be inserted deeper into the plug blade apertures of the receptacledespite the insulative plug cover layer extending over the socket face.It has been determined that a maximum thickness of 0.075 inchesmaintains sufficient plug blade contact within the receptacle whileallowing sufficient material strength for the outlet cover.

Exemplary embodiments of the present invention have the thickness 200within the range of not more than 0.075 inches. It has been found thatthe conventional thickness of 0.080 inches and larger causes concernamong some that sufficient contact will not be made by the plug prongsinto the socket. Reduction of the thickness 200 to less than 0.075inches, and more particularly to a range of 0.020–0.075 inches, permitsthe plug prongs to extend more fully into the socket, relieving many ofthose concerns. In particular embodiments of the present invention, athickness of 0.020 inches may be achieved by use of particularmaterials, such as, but not limited to, polypropylene and polyethylene.In other particular embodiments, the thickness of 0.020 inches may alsobe accomplished by use of a vacuum used during the material flowprocess. As the vacuum evacuates the air within a mold used to form acover plate, the material forming the cover plate may more easily bedrawn into all cavities of the mold. To maximize the strength of thecovering surface while minimizing the thickness 200, it has been foundthat a thickness between 0.030 inches and 0.055 inches reduces thelikelihood of structural failure while maintaining the ability toachieve sufficient contact of the plug prongs within the socket. Tomaximize the contact made by the plug prongs into the socket, it hasbeen found that a thickness within the range of 0.035–0.045 inchesprovides a substantially maximum contact between the plug prongs and thesocket for a covered socket face while providing adequate strength ofthe covering surface. It will be understood by those of ordinary skillin the art that the ranges of thickness disclosed are for the exemplarypurposes of this disclosure and that the present invention is notlimited to these ranges.

In particular embodiments of the present invention, the thickness 200may be accomplished by recessing or reducing the thickness from the backsurface of the cover plate. This enables the front surface of the coverplate to not extend beyond the plane defined in part by the one or morethinned regions of the front surface that extends parallel to the coverplate. This vertical plane sets the boundary for which portions of thecover plate should not extend past, allowing for unobstructed insertionof plug blades into the receptacle through the cover plate. Whileportions of the front face may not extend beyond the vertical plane,they may extend backward.

The aperture punch out region material may be configured to be so thinas to be ruptured even simply by insertion of the prongs of anelectrical plug. The thickness 203 needed for the aperture punch outregions depends upon a number of features including, but not limited to,the material used to form the cover plate, the ruggedness desired forthe punch out region, the ease with which the punch out region should beable to be punched out, the thickness of the surrounding material, andthe tolerable amount of sagging for the region. Preferably, thethickness 203 of the aperture punch out regions is generally less thanor equal to approximately three fourths of the thickness 200 of thesurrounding socket face regions. It has been found that when usingpolyvinylchloride (“PVC”), and a cover plate having a socket face regionwith a maximum thickness of between 0.035 to 0.075 inches, an aperturepunch out region having a thickness of less than approximately 0.030inches is best. This allows for a sufficient difference between thestrength of the punch out region and the strength of the socket faceregion to allow the punch out region to be ruptured by pressure on theregion such as by a plug prong. The specific manner of establishing thethickness, whether through molding or scoring or groove, depends uponthe other factors mentioned above. As shown in FIG. 5, only a portion ofthe aperture punch out region, such as a groove around the perimeter ofthe region or somewhere within the region, needs to be the minimum levelto allow for puncture of the region.

The thin film of material used for the aperture punch out regions may bemade to correspond to substantially all of a particular portion and maybe advantageously made to correspond with cross sectional shapes andpositions of prongs of plugs as illustrated in FIGS. 1A–7. Furthermore,this teaching may be applied to other known plug prong configurations,as well as to those which have not yet been discovered. It is also to beunderstood that the configurations shown in solid and dashed lines inFIGS. 1A through 7 may be mixed and matched in any variety ofcombinations without departing from the spirit and scope of the presentinvention. Furthermore, the various configurations may be located atalternative positions on the base plate without departing from the scopeof the invention. For example, indicators identifying portions to bepunched out for GFCI switches may be located at any position on the baseplate that would correspond to GFCI switches of a predeterminedconfiguration. Other configurations including configurations toaccommodate other plug types may be provided. Additional combinations ofconfigurations including combinations of multiple plug types may beprovided in the same base plate.

While the knock out region outlines in the FIGs. have been described interms of permanently removable portions, it is to be understood that oneor more portions of the base plates 15, 90, 120, and 142 may be providedas replaceable portions, and the replaceable portions may themselveshave indicators such as grooves, ink markings, score lines, oradditional replaceable portions. For example, replaceable portions maybe provided by adapter plates as taught by the disclosure of U.S. Pat.No. 6,642,453, issued Nov. 4, 2003 to Shotey et al. and entitled“CONVERTIBLE ELECTRICAL DEVICE COVER AND METHOD FOR INSTALLING THESAME”, which is incorporated herein by reference.

FIG. 8 is a flow diagram for a method 210 of installing a cover plate toa predetermined electrical outlet configuration. The method begins byproviding a cover plate such as that described above in embodimentsadaptable to more than one possible electrical outlet configuration(Step 213). The installer then selects among the predeterminedconfigurations available on the cover plate (Step 216). As described inassociation with the various embodiments above, the configurations maybe indicated on one side or both the front and back sides of the coverplate. Once the installer has selected a desired configuration, theinstaller creates an aperture at the aperture punch out regionscorresponding to the selected configuration (Step 219). Creating anaperture, as explained previously, may be done by rupturing the thinfilm of material within the aperture punch out regions with a screwdriver or with plug prongs. Last, the installer installs the cover plateonto an electrical outlet (Step 222). Installation may involve manysteps such as attachment of a lid and mounting on the outlet box as wellas other conventional installation steps.

Another advantage of using a cover plate where the plug blade aperturesare covered prior to use is that the cover plate, if provided with anappropriate textured surface for painting, could be painted while on theoutlet cover without concern of paint getting inside the electricaloutlet. Also, in locations where particular outlets are never used, theoutlet remains covered and unexposed. Once the outlet is needed, theuser need only press the plug through the aperture punch out regionsindicated on the surface to puncture the regions and access thereceptacle.

The embodiments and examples set forth herein were presented in order tobest explain the present invention and its practical application and tothereby enable those of ordinary skill in the art to make and use theinvention. However, those of ordinary skill in the art will recognizethat the foregoing description and examples have been presented for thepurposes of illustration and example only. The description as set forthis not intended to be exhaustive or to limit the invention to theprecise form disclosed. Many modifications and variations are possiblein light of the teachings above without departing from the spirit andscope of the invention.

1. A cover plate for an electrical outlet, the cover plate comprising:at least one socket face region having a front surface and a backsurface, the socket face region configured to cover at least oneinsulative socket face of an electrical outlet when the cover plate isinstalled on the electrical outlet, the insulative socket face having aplurality of plug blade apertures extending therethrough, wherein theback surface contacts the at least one socket face when the cover plateis installed on the electrical outlet, the socket face region having afirst thickness between the front surface and the back surface; and aplurality of cover plug blade apertures within the at least one socketface region, the cover plug blade apertures arranged and configured tocorrespond to positions of the plurality of plug blade apertures throughthe insulative socket faces for each of at least two differentinsulative socket face configurations selected from the group consistingof a single round electrical outlet, a duplex electrical outlet and aground-fault circuit interrupt electrical outlet.
 2. The cover plate ofclaim 1, wherein the first thickness is less than or equal to about0.075 inches.
 3. The cover plate of claim 1, wherein the first thicknessis less than or equal to about 0.055 inches.
 4. The cover plate of claim1, wherein the first thickness is less than or equal to about 0.045inches.
 5. The cover plate of claim 1, wherein the cover plug bladeapertures are arranged and configured to correspond to positions of theplurality of plug blade apertures for each of a single round electricaloutlet, a duplex electrical outlet and a ground-fault circuit interruptelectrical outlet.
 6. The cover plate of claim 1, further comprising aplurality of indicators on the front surface of the socket face region,the indicators identifying approximate boundaries of features of theinsulative socket faces for which the cover plug blade aperturescorrespond.
 7. The cover plate of claim 6, wherein the indicatorscomprise ink.
 8. The cover plate of claim 6, wherein the indicatorscomprise at least one groove in at least one of the front and the backsurface of the at least one socket face region.
 9. The cover plate ofclaim 1, further comprising at least one hinge member on the coverplate.
 10. The cover plate of claim 9, further comprising at least onelid hingedly attached to the cover plate.
 11. The cover plate of claim1, further comprising at least one hinge member on each of two adjacentsides of the cover plate.
 12. The cover plate of claim 1, the coverplate comprising a first side and a second side, the first sidecomprising at least a first socket face region corresponding to a firstinsulative socket face configuration and the second side comprising atleast a second socket face region corresponding to a second insulativesocket face configuration different than the first insulative socketface configuration.
 13. The cover plate of claim 1, wherein a groundfault circuit interrupt electrical outlet is one of the at least twodifferent electrical outlet configurations, the cover plate furthercomprising at least one knock out region arranged and configured tocorrespond to a position of a ground fault circuit interrupt electricaloutlet switch.
 14. A cover plate for an electrical outlet, the coverplate comprising: at least one socket face region having a front surfaceand a back surface, the socket face region configured to cover at leastone insulative socket face of an electrical outlet when the cover plateis installed on the electrical outlet, wherein the socket face regionhaving a first thickness between the front surface and the back surface;and a plurality of cover plug blade apertures within the at least onesocket face region, each cover plug blade aperture associated with apredetermined electrical outlet configuration, wherein the plurality ofcover plug blade apertures are configured to align with electricaloutlet configurations for each of at least two different electricaloutlet configurations selected from the group consisting of a singleround electrical outlet, a duplex electrical outlet and a ground-faultcircuit interrupt electrical outlet.
 15. The cover plate of claim 14,wherein the first thickness is less than or equal to about 0.075 inches.16. The cover plate of claim 14, wherein the first thickness is lessthan or equal to about 0.045 inches.
 17. The cover plate of claim 14,wherein the cover plug blade apertures configured to align withelectrical outlet configurations for each of a single round electricaloutlet, a duplex electrical outlet and a ground-fault circuit interruptelectrical outlet.
 18. The cover plate of claim 14, further comprising aplurality of indicators on the front surface of the socket face region,the indicators identifying approximate boundaries of features of theinsulative socket faces for which the cover plug blade aperturescorrespond.
 19. The cover plate of claim 14, the cover plate comprisinga first side and a second side, the first side comprising at least afirst socket face region corresponding to a first electrical outletconfiguration and the second side comprising at least a second socketface region corresponding to a second electrical outlet configurationdifferent than the first outlet configuration.
 20. The cover plate ofclaim 14, wherein a ground fault circuit interrupt electrical outlet isone of the at least two different electrical outlet configurations, thecover plate further comprising at least one knock out region arrangedand configured to correspond to a position of a ground fault circuitinterrupt electrical outlet switch.